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Mid Atlantic Impreza Club Forum sponsored by Annapolis Subaru |
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11-29-2007, 05:31 PM | #1 |
Scooby Guru
Member#: 15359
Join Date: Feb 2002
Chapter/Region:
MAIC
Location: Fairfax, VA
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Reverse Intake Manifold Project
Well,
My project for this winter is to reverse the intake manifold on my car. I'll update this thread as I make progress on the project, should take about 3 weeks to complete. I started by removing the charge pipes, intake manifold, alternator, and turbo. Knowing that I wanted to significantly reduce the length of the intercooler piping, I decided to reverse its direction. The easiest way to do this seemed to be to clock the green so the compressor outlet faced the passenger side strut tower. This required grinding off all the bosses for the IWG. Not a problem, since my car has a TIAL 38. Here's a picture of the turbo mounted in the car. I should be able to use the 90 degree coupling from the old piping. On the intake manifold, it was necessary to grind off the boss on the bottom used to secure the main engine wiring harness. This allows the intake pipe to fit in the same location. Today I built the brackets to secure the alternator in it's new position, and welded up the extra bung on the coolant header tank I'm not using because my green is an oil cooled only turbo. More to follow Duncan
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11-29-2007, 07:00 PM | #2 |
Scooby Specialist
Member#: 100150
Join Date: Nov 2005
Chapter/Region:
MAIC
Location: NC
Vehicle:02 V9 STi 6spd HTA Green, Built EJ205 |
wow. Great idea. I already have the rotated manifold but didn't think about the piping bend from the turbo. It is kind of a nasty bend that has to be made. Look forward to seeing how it turns out.
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11-29-2007, 07:22 PM | #3 |
Scooby Specialist
Member#: 64805
Join Date: Jun 2004
Chapter/Region:
MAIC
Location: The Wild Serengeti Suburbs
Vehicle:2008 SG6 Model D BlueRallyWorld |
Sounds good. Hope everything works out for you. Keep us posted w/ pics
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11-29-2007, 08:55 PM | #4 |
Scooby Specialist
Member#: 131915
Join Date: Nov 2006
Chapter/Region:
MAIC
Location: Richmond/Va Beach
Vehicle:2007 WRX sexy white pearl |
just saw this car in person yesterday. it looks NASTY!
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11-29-2007, 09:22 PM | #5 |
Scooby Specialist
Member#: 81725
Join Date: Feb 2005
Chapter/Region:
MAIC
Vehicle:73 zcar amidst ls2 swap |
dunk,
fire an email over to scott (at) usrallyteam (dot) com and tell him i sent you and what you're working on... he may have a goodie he'd like you to try on for size |
11-29-2007, 11:47 PM | #6 |
Scooby Specialist
Member#: 52662
Join Date: Jan 2004
Chapter/Region:
MAIC
Location: frederick, maryland
Vehicle:2009 WRX. 06 Baja 17 Crosstrek 85 brat |
cool beans, looks like its going to be fun.
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11-30-2007, 06:38 AM | #7 |
Scooby Guru
Member#: 15359
Join Date: Feb 2002
Chapter/Region:
MAIC
Location: Fairfax, VA
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11-30-2007, 09:14 AM | #8 |
Scooby Specialist
Member#: 7764
Join Date: Jun 2001
Chapter/Region:
MAIC
Location: State of Confusion
Vehicle:16 Jeep Renegade Its Trailrated Yo |
ummm why would someone want to do this??
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11-30-2007, 09:23 AM | #9 |
Scooby Specialist
Member#: 41626
Join Date: Aug 2003
Chapter/Region:
NWIC
Location: Mt Vernon, WA
Vehicle:SPB We make people quit teh internet |
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11-30-2007, 09:39 AM | #10 | |
Scooby Guru
Member#: 10852
Join Date: Oct 2001
Chapter/Region:
MAIC
Location: Cleveland / UMD College Park
Vehicle:Then : JDM Ver 7 STi Now : E46 M3 / MKVI GTI |
Quote:
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11-30-2007, 07:22 PM | #11 |
Scooby Guru
Member#: 15359
Join Date: Feb 2002
Chapter/Region:
MAIC
Location: Fairfax, VA
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Made a little more progress today, here's some new pictures.
This is from mock up of the intercooler pipes. Nice short run for the hot pipe. Nothing is welded yet, just set in place until I'm sure it's where I want it. Good pictures of the beginning of the cold side plumbing, as well as a front shot of the belt. You can see the timing belt idler pulley (thanks Vern). Just had to drill and tap the hole on the alternator bracket to the 10x1.25 size for the pulley. You can also see the bracket that holds up the alternator in this picture. Close up picture of the throttle body. You can see I've removed the cruise control arm. This is the coolant header tank top. As I have an oil cooled turbo, I decided to remove the nipple for the coolant line and weld it up. That way I don't have to worry about a hose cap rupturing at the track. Checking to make sure the intake still fits. Trying out some possible locations for the BOV. Top of that intercooler pipe will be cut off and rotated to face the center of the car. I'm hoping to finish up the intercooler piping this weekend, that way I can start breaking everything down and getting it prepped for paint. thanks Duncan |
11-30-2007, 09:17 PM | #12 |
Scooby Guru
Member#: 113734
Join Date: Apr 2006
Chapter/Region:
South East
Location: Charleston SC
Vehicle:2023 FL5 Type R Subaruless |
Why don't you just elimnate the Resivour completly, seems pointless to keep it
all you have to is get a longer silicone hose(from autozone) and re-route to where its going in the first place you can see how I did mine in this pic |
11-30-2007, 09:28 PM | #13 |
Scooby Guru
Member#: 15359
Join Date: Feb 2002
Chapter/Region:
MAIC
Location: Fairfax, VA
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I would, but I'd need to have a filler neck put on my radiator.
Duncan |
11-30-2007, 09:40 PM | #14 |
Scooby Specialist
Member#: 46407
Join Date: Oct 2003
Chapter/Region:
South East
Location: Way souf of ATL
Vehicle:2002 WRX blew |
I look forward to seeing the outcome.
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11-30-2007, 10:28 PM | #15 |
Scooby Specialist
Member#: 81725
Join Date: Feb 2005
Chapter/Region:
MAIC
Vehicle:73 zcar amidst ls2 swap |
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12-01-2007, 12:39 AM | #16 |
Scooby Specialist
Member#: 46177
Join Date: Oct 2003
Chapter/Region:
MAIC
Location: Baltimore, MD
Vehicle:2002 WRB WRX 99 RSTi Coupe |
Just get a STi Radiator.
James |
12-01-2007, 10:02 AM | #17 |
Scooby Guru
Member#: 15359
Join Date: Feb 2002
Chapter/Region:
MAIC
Location: Fairfax, VA
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12-01-2007, 11:03 AM | #18 |
Scooby Guru
Member#: 113734
Join Date: Apr 2006
Chapter/Region:
South East
Location: Charleston SC
Vehicle:2023 FL5 Type R Subaruless |
I have one, sell it cheap
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12-01-2007, 11:26 PM | #19 |
Big Ron
Super Moderator Member#: 18062
Join Date: Apr 2002
Chapter/Region:
MAIC
Location: I can save you a ton of cash
Vehicle:on car parts so PM me b4 j00 buy |
Looks great so far buddy! We actually have decent intraweb speeds for now so I can see this. I'm sure you've thought of this, but not would be a great time for that APS inlet. Also, some Grimmspeed phenolic gaskets. I can get you a deal on the gaskets, but no deals are to be had on APS stuff.
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12-02-2007, 10:34 AM | #20 |
Scooby Guru
Member#: 10852
Join Date: Oct 2001
Chapter/Region:
MAIC
Location: Cleveland / UMD College Park
Vehicle:Then : JDM Ver 7 STi Now : E46 M3 / MKVI GTI |
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12-02-2007, 05:19 PM | #21 |
Big Ron
Super Moderator Member#: 18062
Join Date: Apr 2002
Chapter/Region:
MAIC
Location: I can save you a ton of cash
Vehicle:on car parts so PM me b4 j00 buy |
Not debbil now that I know of. You mean the gaskets themselves or Grimmspeed? Both are fine still as far as I know unless something has changed within the last 3 months as my world's slowest internet has kept me off the forums.
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12-02-2007, 05:49 PM | #22 |
Scooby Guru
Member#: 15359
Join Date: Feb 2002
Chapter/Region:
MAIC
Location: Fairfax, VA
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Well, made some more progress over the weekend. Got all the pipes cut and welded up, thanks to a friends neighbor, Javier, who is a Navy Hull Technician. Also big thanks to All Aspects Motorsports for lending me the TIG welder. Now onto the pictures.
Picture of the hot side tubing. I decided to place the BOV here for ease of packaging. Front pipe all tack welded up. Another shot of the same, different angle. Tack weld on the charge pipe. After tacking everything in place it was carefully removed from the car, and welded on the bench. Here's some pictures of the completed pieces off the car. Finally, everything was reinstalled in the car to check for fitment. I've also decided to remove the coolant header tank from the system. I'll purchase a weld on filler neck and transfer it to the radiator. Next I'll start tearing everything down from mock up and prepping it for paint. Duncan |
12-02-2007, 08:41 PM | #23 | |
Scooby Guru
Member#: 10852
Join Date: Oct 2001
Chapter/Region:
MAIC
Location: Cleveland / UMD College Park
Vehicle:Then : JDM Ver 7 STi Now : E46 M3 / MKVI GTI |
Quote:
Dunk, your setup looks really clean, it's gonna be the best bolt-on engine bay ever. |
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12-02-2007, 08:46 PM | #24 |
Scooby Specialist
Member#: 149890
Join Date: May 2007
Chapter/Region:
NESIC
Location: Somewhere in CT
Vehicle:09 Forester Green |
the manifold looks great, keep up with the great pics
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12-02-2007, 09:12 PM | #25 |
Scooby Specialist
Member#: 165749
Join Date: Dec 2007
Location: Detroit, MF'er!
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Who makes that intake manifold? Is it a STi manifold? If not, do they make one for the non-turbo engines? more specifically a '07 2.5i??? Nice setup, looks like you cut out some bull**** and cleaned it up well. Hope it turns out great. can't wait to see the finished project.
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